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I have looked and looked for a 415 chain kit for our 250's and can't find one. Anybody know if anyone is making a kit for our bikes. I will be talking to a company to make me some so I will keep everybody up to date want it will cost.
 

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Unless you're racing, there's minimal gains from 415 sprockets. More maintenance and more cost over same time-frame compared to stock.

I got 428 sprocket kit for my Ninja 250 race-bike. Has most of weight-savings of 415, but much longer lifetime. It lasted 2-seasons (+45 days/year @ track). Then I went to 415 which lasted less than 1 season. Check out these places where I got sprocket kits for my Ninja 250 race-bike.
Home | Sprocket Specialists - World's Best Sprockets Since 1950 (makes custom sprockets to your specifications)


You can also research and buy parts individually. Get sprocket-mounting dimensions from JT-catalogue: http://www.jtsprockets.com/catalogue/model/s271/. Then go through all other listings to see what other bikes use same mounting but in 415 chainsize and these those sprockets.
 

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Honda: INNOVA125i(2010); CBR250R(2013)
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The facts:
1. Most of the profit is due to the rear sprocket replacing. Because the diameter is larger (the matter of inertia), and also because it is larger, which means that you save more weight.
2. In the front sprocket the situation is reversed, a small diameter means less effect on inertia, and a small size means less effect on weight reduction.
3. The load on the small sprocket is more then a double, so its wear will also be more then a double.

My conclusions:
So it almost makes sense(to me) not to bother about aluminum for the small sprocket. I think you can find one 415 made of hard metal (not aluminum), which still has holes for weight relief, if not, you can drilling these holes by yourself.
 

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Don't forget smaller chain saves a lot of weight as well.

I don't think you're going to find aluminium front-sprocket. The 428 & 415 ones I used were steel.

Yup, load difference is ratio of teeth. So front-sprocket faces about 3x higher load than rear.
 

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here's a 420... not sure where that fits in the sizing spectrum
 
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